Method and apparatus for discontinuous applications, at a constant pitch, of controlled quantities of absorbent material in granules

ABSTRACT

A device for transforming a continuous and controlled flow of absorbent material in granules into an intermittent flow for providing the material to a receiving member movable along a direction X, including a feed manifold, an outlet and a main body, placed between the feed manifold and the outlet, configured to cause the absorbent material to flow along a direction (Y′-Y′) coinciding with the respective axes of symmetry of the feed manifold, the outlet nozzle and the main body; wherein within the main body a movable element is housed, capable of moving alternately between a first and a second working position, such that when the movable element is in the first position, it forms a first accumulation chamber of the material, and a first discharge duct of the material, and when the movable element is in the second position, it forms a second accumulation chamber and a second discharge duct.

This application is a divisional of U.S. Ser. No. 14/204,005, filed Mar.11, 2014, which claims priority of Italian Application Serial No.TO2013A000195, filed Mar. 12, 2013, the contents of each of which arehereby incorporated by reference herein.

TECHNICAL FIELD

The present description relates to an apparatus and the relative methodsuitable for discontinuous applications, at a constant pitch, ofcontrolled quantities of material, for example absorbent material ingranules on a moving substrate, designed to be advantageously used, forexample, as an absorbent structure in disposable sanitary hygieneproducts such as pant-type wearable diapers, in all their possibleconfigurations and uses, or rather, both in the open configuration andin the closed configuration, better known as “training pants” or“pull-ons”, both for child and adult use.

TECHNOLOGICAL BACKGROUND

In the field of disposable sanitary hygiene articles at the end of the1980s, absorbent material in granules was introduced for forming theirabsorbent structure, which was previously composed of just cellulosefibers.

The absorbent material in granules that is normally used in this type ofdisposable hygiene products is composed of super-absorbent polymerscapable of absorbing and retaining large quantities of liquids.

Super Absorbent Polymers (SAP) can, in turn, have granules of differentsizes and shapes, according to the different production methods.

The production of an absorbent structure can be carried out in severalways. One of the most common methods is carried out by depositing and/ormixing the absorbent polymers granules on a strip composed of syntheticand/or natural fibers that can be absorbent, for example cellulosefibers.

The desire of all manufacturers of disposable sanitary hygiene productsis to be able to concentrate the absorbent material in areas where it ismost used, i.e. to create discontinuous applications of the absorbentpolymer granules, always maintaining control of the weight and thegeometric parameters of the application, such as the length and width ofthe applied dose and pitch of application between the various doses; soas to achieve a higher quality product that, at the same time, resultsin a saving in terms of cost, and creates products with a lowerenvironmental impact as they are made with a smaller quantity ofmaterials.

Systems are known in the art that are able to apply a quantity ofabsorbent polymer material in granules in a discontinuous mannersuitable for producing absorbent structures for disposable sanitaryarticles. According to the known, well described embodiments, forexample, in patent document EP 1 621 165 A1, such systems consist of arotary dispensing cylinder provided, on its outer surface, with aplurality of slots and/or recesses arranged at the deposition area, andhaving dimensions that ensure the deposition of the correct quantity ofabsorbent material in granules or SAP. The rotary dispensing cylinder isnormally placed at the bottom of a reservoir from which it picks up thematerial in granules. Subsequently, by rotating, the cylinder carriesthe slots and/or recesses, filled with SAP, into a second area ordischarge area where it releases it. The discharge area is normallydiametrically opposite to the loading area, and the material dischargedfrom the dispensing cylinder can be deposited on a moving strip.

The inventors have observed that apparatus such as the one describedabove have numerous limitations and/or problems such as, for example,the control of the quantity of the absorbent material in granulesapplied to each product, which can be done only in an indirect manner.

Indeed, the weight of material introduced in the production method ofthe absorbent structure can only be determined with the aid of theapparent density of the material in granules, in other words, thequantity of SAP that is required for depositing on the absorbentproducts is defined solely by the volume of the slots and/or therecesses present on the outer surface of the dispensing roller, whichare intended to be filled by said absorbent polymeric material ingranules.

It should be recalled that the density or volumic mass of a body isdefined as the ratio between the mass of a body and its volume.

The definition of density provided above refers to a quantity of solidand homogeneous matter, i.e. without internal voids. This value is alsoknown as the real or absolute density, since it only takes into accountthe volume of the solid fraction.

For solid materials with closed cavities, with open cavities or spongystructures, or for granular matter contained in the recipients, such assand, grains or as in our case absorbent material in granules, theconcept of apparent density of a body is introduced, which is calculatedin a manner formally analogous to the absolute density, but takes intoaccount the total volume occupied by the solid, thus its externaldimensions, including the empty spaces present inside.

This type of control has very important limitations related,specifically, to the variability of the apparent density. Indeed, theapparent density changes according to the pressure head variation ingranular material present in the loading reservoir, the variation in theenvironmental conditions (temperature, humidity) and not least to thevariation in size of the granules themselves, which of course can varybetween one supplier and another, but also to the variation inproduction batches from the same supplier.

Furthermore, the slots and/or recesses have difficulty filling andemptying their contents with increasing velocities of the productionmachines. To overcome this difficulty, dispensing cylinders are providedwith gripping and releasing means of the absorbent material in granules.To do this, the bottom of the slots and/or recesses of the dispensingcylinder are rendered permeable to air, and connected to a source ofsub-atmospheric pressure during the loading phase, and subsequently, toa high pressure pneumatic source during the phase of expulsion ordischarge.

This system, while solving the problem of filling and emptying of thedispensing roller in high-velocity production lines, in turn, generatesnew problems such as, for example, increasing the complexity andconsequently the cost of the dispensing roller and the increase inmaintenance operation costs due to the need to always keep theair-permeable area of the slots and recesses clean.

In addition to what has already been said, the problem linked to thechange in production size, and therefore the specifications, of theabsorbent structure, must not be forgotten. Indeed, it is evident thateach format of the absorbent structure is also characterized, inaddition to its dimensions, by the quantity and distribution of theabsorbent material in granules. Therefore, each of the said formats ofthe absorbent structure requires its own specific dispensing roller,which, obviously, must be replaced when the size of the product to beproduced changes.

OBJECT AND SUMMARY

The object of the present invention is to provide instructions forproducing a device capable of carrying out the applications of discretequantities of material in granules, for example, of shape- andweight-controlled absorbent polymers, on a moving receiving means, forexample, a continuous sheet, designed, for example, to be advantageouslyused as an absorbent structure in disposable sanitary hygiene products.

According to the invention, this object is achieved thanks to anapplication device having the characteristics referred to specificallyin the claims that follow.

The invention also relates to a corresponding production method.

The claims form an integral part of the technical disclosure hereinprovided in relation to the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, purely by way of non-limitingexample, with reference to the attached drawings, wherein:

FIGS. 1 and 6 are, respectively, the schematic view of two types ofproduction methods for the construction of absorbent structures, whichuse the equipment, subject of the present invention, of FIG. 2,

FIG. 2 is a schematic perspective view in half-view and half-sectionaccording to the axis II-II of FIG. 1 of the apparatus, subject of thepresent invention, according to a preferred embodiment.

FIGS. 3 to 5 are schematic sectional views of the apparatus of FIG. 2,in the various processing steps,

FIG. 7 is a schematic perspective view of the absorbent structureproduced with the production method of FIG. 1,

FIG. 8 is a schematic perspective view of the absorbent structure madewith the production method of FIG. 6,

FIG. 9 is a schematic view of the movement that is carried out by themovable component of the apparatus of FIG. 2,

FIG. 10 is a diagram of the law of motion of the component of FIG. 9.

DETAILED DESCRIPTION OF EMBODIMENTS

In the following description, various specific details are illustratedaimed at a thorough understanding of the embodiments. The embodimentscan be implemented without one or more of the specific details, or withother methods, components, materials, etc.

In other cases, known structures, materials or operations are notillustrated or described in detail to avoid obscuring the variousaspects of the embodiments

The reference to “an embodiment” in the context of this descriptionindicates that a particular configuration, structure or feature,described in relation to the embodiment, is included in at least oneembodiment. Therefore, phrases such as “in an embodiment”, possiblypresent in different places of this description do not necessarily referto the same embodiment.

Furthermore, particular conformations, structures, or features can becombined in any suitable manner in one or more embodiments.

The references used herein are for convenience only and therefore do notdefine the field of protection or the scope of the embodiments

With reference to FIGS. 1 and 6, numerals 10 and 10′ indicate twoproduction methods for producing absorbent structures or parts of them,which employ a device 20, according to the preferred embodimentillustrated in FIG. 2, which makes them capable of carrying outdiscontinuous applications at a constant pitch P of discrete quantitiesof controlled weight and size 250 of absorbent polymer material ingranules 310 on a continuous strip 50, 60 that moves in the advancingdirection X, supported by appropriate support means, which can be eithera roller or a conveyor belt 40, 600.

Said sheet 50, 60, once supplied with the absorbent material in granules310 can be advantageously used, alone, or in combination with othermaterials, such as absorbent structures in disposable sanitary hygieneproducts. Said strip or sheet 50 or 60 can be made from synthetic and/ornatural fibers that can be absorbent, such as for example cellulosefibers as shown in the production method of FIG. 1 or, alternatively,they can use a sheet of non-absorbent fibers such as, for example, astrip of non-woven fabric, as shown in the production method of FIG. 6.

The production methods 10 or 10′, respectively schematized in FIG. 1 andFIG. 6, can be composed of a dispenser 30, arranged to provide acontinuous flow 320 of absorbent material in granules of constantlycontrolled weight, to a device 20, produced according to the preferredembodiment illustrated in FIGS. 2 to 5.

A type of absorbent material in granules 310 frequently used in themanufacture of absorbent structures for disposable hygiene products,which can be advantageously managed by the device 20, according to theembodiment illustrated in FIG. 2, can be the super absorbent polymer ofmedium permeability Z3403 produced and marketed by Evonik Industries AG,Rellinghauser Strasse 1-11, 45128 Essen, Germany.

A continuous dispenser 30 particularly suitable for this type ofproduction method can be the weight subtraction dispensing system modelAI-405-105R-1 produced and marketed by Acrison. Inc., 20 Empire Blvd,Moonachie, N.J. 07074 U.S.A.

This type of dispenser 30 is able to provide a constant-mass flow 320 ofabsorbent polymer material in granules 310, independently from anyvariable that can influence it, such as the pressure head variation inthe loading reservoir, or the variation of apparent density linked toany one of the factors that may condition it. Indeed, the dispenser 30is normally provided with a control system of the weight, whichconstantly checks the weight variation according to the quantity ofmaterial 310 provided to the downstream process in the unit of time.Said control system is able to properly modulate the flow 320 in orderto always maintain the mass of the material 310, supplied to thedownstream process, within the predefined tolerance limits.

The sizing and selection of the continuous dispenser 30 is carried outby multiplying the number of absorbent structures that the productionline must produce in the unit of time by the quantity of absorbentmaterial in granules 310 of each dose 250 applied on each of saidabsorbent structures.

For example, considering that the methods and apparatus suitable for theproduction of the absorbent structures illustrated in FIGS. 1 and 6 canadvantageously produce 700 absorbent structures per minute, with doses250, for example, from 10 grams of absorbent material in granules 310,it follows that the continuous dispenser 30 will be able to provide acontinuous and controlled flow 320 of 420 kg/hour of the said materialin granules 310.

A unit or device 20 can be placed downstream of the dispensing system30, which transforms the continuous flow 320 of polymer in granules 310into an intermittent flow consisting of a plurality of determined anddiscrete quantities (or doses) 250 of said absorbent material ingranules 310 and applies the said doses 250 at a constant pitch P on therelative moving substrate 50, 60.

In the preferred embodiment, as illustrated in FIGS. 3 to 5, theconstant-mass flow 320 of the absorbent polymer material in granules 310is supplied to the apparatus or device 20 through the mouth 215 of thefeed manifold 210 and the material then comes out in weight- andsize-controlled doses 250, from the outlet nozzle 500 after havingcrossed the main body 200 located between said feed manifold 210 andsaid outlet nozzle 500. The absorbent material in granules 310, incrossing the device 20, flows along a direction Y′-Y′, coincident withthe respective axes of symmetry of the feed manifold 210, the outletnozzle 500 and the main body 200, as clearly illustrated in FIG. 2. Inthe preferred embodiment, the main body 200 of the apparatus or device20 has an inner section, transverse to the crossing direction Y′-Y′ ofsaid material 310, of a quadrilateral shape with all right angles.

The main body 200 has, in addition, an upper part 270 and a lower part271.

The material in granules 310 enters inside the main body 200 of the saidapparatus 20, by crossing the feed manifold 210, as is clearlyhighlighted in FIG. 3.

In the preferred embodiment illustrated in FIG. 2, a movable element 240is housed within said main body 200, which can have a wedge-shape havinga first and a second end 260, 290 and two side faces 241, 242,symmetrical along the crossing direction Y′-Y′ of the flow of absorbentmaterial in granules 310, converging toward the first cusp end 260.

The first cusp end 260 of the movable element 240, in the preferredembodiment of FIG. 2, is oriented upstream with respect to the crossingdirection Y′-Y′ of the flow of material in granules 310.

Also in the preferred embodiment of FIG. 2, the two side faces 241, 242of the movable element 240, form with the wider second end 290, a firstside edge 291 and a second side edge 292, respectively; furthermore,said movable element 240 can be connected at said second end 290 to ashaft 295, free to rotate around its axis X′-X′, in order to allow themovable element 240 to make a 20 oscillation about the said axis X′-X′between a first working position represented in FIG. 3, and a secondworking position illustrated in FIG. 5.

The shaft 295 is, in turn, connected to the main body 200 by means of apair of suitable supports 235, which can be formed by bearings of anytype, in the preferred embodiment of FIG. 2 they are rigid ballbearings.

The said shaft 295 is, furthermore, connected with mechanical connectingmeans 265 to appropriate actuator means 245.

In the preferred embodiment of FIG. 2, the said mechanical connectingmeans 265 can be made from components of a constant velocity joint ofthe type ROTEX GS28 98SH produced and marketed by KTR KUPPLUNSGSTECHNIKGmbh, Rodder Damm 170, 48432 Germany.

Also in the preferred embodiment of FIG. 2, appropriate actuating means245, suitable for this type of use, could be a servomotor of the typeMSK 071 E-0300 and a control system HMS 54A BASIV V3 (not illustrated inthe figures), produced and marketed by Bosch Rexroth AG, Electric Drivesand Controls, P.O. Box 1357, 97803 Lohr, Germany.

In the preferred embodiment, as already mentioned and clearlyhighlighted in FIGS. 3 to 5, the actuating means 245 are able to movethe movable element 240 between a first and a second working position,causing it to oscillate through an angle 2θ that can be between 10° and30°, with a preferred value of 20° (θ=10°), as shown schematically inFIG. 9.

An expert in the field will appreciate that the inner surface 275 of theupper end 270 of the main body 200 in the preferred embodiment issuitably shaped to allow the first end 260 of the movable element tomove between the two working positions, whilst always remaining adherentto the said inner surface 275.

When said movable element 240 is located in the first working position,which in the preferred embodiment is illustrated in FIG. 3, it formswith the first inner side surface 220 and with the inner transversewalls 221 and 222 of the main body 200 of the apparatus 20, a firstaccumulation chamber 230, which is transversely bordered by the two saidtransverse walls 221 and 222 (FIG. 2) and laterally by the first innerside surface 220 and the first side face 241 of the movable element 240,so that the first side face 241 of said movable element 240 extendsbetween the two inner transverse walls 221 and 222 of the main body 200,and connects, with its first cusp end 260 and with its first side edge291 of the second end 290, the inner surface 274 of the upper end 270 ofthe main body 200 to the lower part of the first inner side surface 220of the main body 200.

When the movable element 240 is located in the first working position,in addition to forming the first storage chamber 230, it forms a firstdischarge duct 233 with its second side face 242 in cooperation with thetwo inner transverse walls 221, 222 and with the second inner sidesurface 223 of the main body 200, as clearly illustrated in FIG. 3.

The apparatus 20 remains in this configuration for the time required tocollect the necessary quantity of absorbent polymer material in granules310 for the formation of a single dose 250 inside the first accumulationchamber 230.

When the loading operation of the absorbent polymer material in granules310 in the first accumulation chamber 230 is completed, the movableelement 240, thanks to the servomotor 245, is moved with a suitablevelocity profile, toward the second working position, represented inFIG. 5, wherein the movable element 240 forms the second accumulationchamber 251 and the second discharge duct 253. In this second workingposition, the movable element 240 forms, with the second inner sidesurface 223 and the inner transverse walls 221 and 222 of the main body200 of the apparatus 20, a second accumulation chamber 251 which istransversely bordered by the two said transverse walls 221 and 222, andlaterally by the second inner side surface 223 and the second side face242 of said movable element 240, so that said second side face 242 ofsaid movable element 240 extends between the two inner transverse walls221 and 222 of the main body 200, and connects, with its first cusp end260 and with its second side edge 292 of the second end 290, the innersurface 274 of the upper end 270 of the main body 200 to the lower partof the second inner side surface 223 of the main body 200.

Simultaneously, the movable element 240 moving from the first to thesecond working position, forms a second discharge duct 253 with itsfirst side face 241 in conjunction with the two inner transverse walls221 and 222 and with the first inner surface 220 of the main body 200,from which the absorbent material in granules 310 flows of the dose 250previously collected in the first accumulation chamber 230.

In the preferred embodiment 20, illustrated in FIG. 2, the first and thesecond accumulation chambers 230, 251 formed by the movement between thefirst and second working positions of the movable element 240 with theinner surfaces 220, 221, 222, 223 of the main body 200 are characterizedin that they ensure the sealing of the absorbent material in granules310. Said sealing can be effectively obtained by appropriate couplingtolerances between the surfaces 241, 242, 243, 244 of the movableelement 240 and the inner surfaces 220, 221, 222, 223 of the main body200. In the preferred embodiment 20, it is possible to obtain a distancefrom 0.05 to 0.2 mm between the two connecting surfaces 243, 244 betweenthe first and second side faces 241, 242 of the movable element 240 andthe respective inner transverse walls 221, 222. Similarly, the samedistance can be obtained between the first cusp end 260 of the movableelement 240 and the inner surface 274 of the upper end 270 of the mainbody 200. Also in the preferred embodiment 20 of FIG. 2, however, thefirst and second side edges 291, 292 of the second end 290 of themovable element 240 can come in contact with the respective first andsecond inner surfaces 220, 223 of the main body 200.

In the preferred embodiment, the movable element 240 is moved betweenthe two working positions, clearly highlighted in FIGS. 3 and 5, with avelocity profile that is represented in the upper part of the graph ofFIG. 10, from which it can be appreciated, by way of example, that inview of a cycle time T=0.00857 seconds, necessary for the production ofan absorbent structure 310 in a production line that produces 700articles per minute, the time t that it takes for the movable element240 to move between the said two working positions can be between 15%and 40% of the cycle time, with a preferred value of 25%, which in thisspecific case would be t=0.00214 seconds.

The skilled person will appreciate that said velocity profile, incombination with the constant control of both the mass of the materialin granules 310 of the flow 320 carried out by the dispenser 30, and thetime of exposure to the said flow 320 of the relative accumulationchamber 230, 251, allows the device 20, in the preferred embodimentillustrated in FIG. 2, to produce a multiplicity of doses 250, allhaving the same quantity, in terms of weight, of absorbent material ingranules 310.

FIG. 4 clearly shows how the fast movement of the movable element 240between the two working positions minimizes the risk that there could bea contamination of granules of absorbent material 310 in those areas ofthe sheet 50, 60 which should remain devoid of granules, indeed, thespeed of the movement minimizes the quantity of material that mightaccidentally fall into the discharge duct before it is closed in therespective accumulation chamber, as clearly shown in FIG. 5.

FIG. 4 also clearly illustrates, in the preferred embodiment, thedischarge operation of the material in granules 310 is favored by thepresence of air inlets 280 located on the upper part 270 of the mainbody 200.

Indeed, these air inlets 280, which in the preferred embodiment can beslots or holes, allow the air flow 285 to fill the void that isgenerated in the respective discharge ducts 233, 253 when the granularmaterial 310 flows toward the output nozzle 500, which, in turn, servesto convey it onto the moving sheet 50, 60.

The skilled person will appreciate the fact that the said openings 280also favor the loading step of the material 310, facilitating theevacuation of the air present in the respective accumulation chambers230, 251, as shown schematically in FIGS. 3 and 5.

While the apparatus 20 carries out the said operations, the dispenser 30delivers a continuous, constant-mass flow 320 of absorbent polymermaterial in granules 310 to the mouth 215 of the feed manifold 210,filling, as such, alternately, the two accumulation chambers 230, 251,which, subsequently, will be emptied when they transform into therespective discharge ducts 233, 253.

The cyclic repetition of the operations just described allows thetransformation of the continuous, constant-mass flow 320 of theabsorbent polymer material in granules 310 into an intermittent flowconsisting of a plurality of discrete determined quantities or doses 250of absorbent material in granules 310 that can be deposited on asubstrate or sheet 50, 60 that, in the production methods of FIGS. 1 and6 that use the device 20 according to the preferred embodiment of FIG.2, for example, can move along the working direction X at a linearvelocity of 4.667 m/s, which is, in fact, the velocity required toproduce 700 absorbent structures per minute, each having a length of 400mm.

It will not escape the skilled person that the left to right motion ofthe X direction used in the figures attached to the present descriptionis only used for indicative purposes, since the apparatus of the presentinvention can work equally well in the opposite direction, i.e. fromright to left.

In the preferred embodiment of the device 20, as clearly represented inFIGS. 1 to 6, the output nozzle 500 can be connected to the lower part271 of the main body 200 by means of a manifold 400 interposed betweensaid two elements 500, 200.

The manifold 400, in the preferred embodiment of FIG. 2, is providedwith a reservoir for pressurized air 410, which surrounds the outerperimeter of the manifold 400 itself, and that serves to supply theopenings 420 located at the connecting edge 520 of the nozzle 500 withthe manifold 400, and is able to generate a high speed air flow 450within said output nozzle 500. The velocity of the airflow 450 may varyfrom 100 to 300 m/s.

In the preferred embodiment, this characteristic is achieved with holes420, created on the four sides of the manifold 400, having a diameterbetween 1 and 2.5 mm and placed at a distance between 5 and 15 mm; in afurther preferred configuration, said holes may have a diameter of 1.5mm at a distance of 10 mm.

The air flow 450 performs two fundamental functions: the first is togenerate a sub-atmospheric pressure level at the entrance of the outletnozzle 500 thanks to the Venturi effect, generated by the high speedair, which, in cooperation with the airflow 285 flowing through the airinlets or openings 280, is able to extract the dose 250 of the materialin granules 310 accumulated within the respective accumulation chambers230 and 251 with greater energy, as clearly illustrated in FIG. 4; thesecond function is to perform a lamination of each individual dose 250.Indeed, when the movable element 240 moves between the two workingpositions, and opens the relative discharge duct 233, 253, the materialin granules 310 of the single dose 250, previously contained in thecorresponding accumulation chamber 230, 251, is extracted in a block,also by virtue of the pressure gradient generated by the Venturi effectof the air flow 450. As soon as the granules 310 of the dose 250 arecaptured by the airflow 450, they are accelerated to a higher speed withrespect to that possessed by the entire dose 250 in the initialdischarge step, with the consequence of carrying out a stretching orlamination of the dose 250 itself. Thanks to this effect, or rather,thanks to the adjustment of the airflow 450 velocity, the length 72, 82of the single dose 250 can be controlled and varied, if necessary.

In the preferred embodiment, the airflow 450 velocity can be varied bysuitably adjusting the value of the air pressure inside the reservoir410. Adequate air pressure values are between 0.3 and 4 bars,particularly preferred are values between 0.7 and 1.5 bars.

A simple and effective system to adjust said pressure level is toconnect the reservoir 410 to the apparatus that generates pressured air,interposing between them a pressure-adjusting device of the typeR73G-3GK-NMR, produced and marketed by Norgren SpA, via Trieste 16,20871 Vimercate (MB).

The outlet nozzle 500, in the preferred embodiment, as well asperforming the functions of conveying the dose 250 of absorbent granularmaterial 310 toward the moving sheet 50, 60, and defining andcontrolling the length 72, 82, also performs the function of controllingthe width 75, 85 of each single dose 250 of granular material 310applied on the said sheet 50, 60, so that the width 75, 85 of the saiddoses 250 is determined precisely by the width 550 of the end portion ofthe outlet nozzle 500.

In a further preferred configuration, not shown in the attached figures,in order to ensure a better control of said width 75, 85 of the doses250, the main elements of the apparatus 200, or rather, the feedmanifold 210, the movable element 240, the main body 200, the compressedair manifold 400 and the outlet nozzle 500, are produced so that theyall have an inner duct width for the passage of absorbent material ingranules 310 equal to the width 75, 85 required for the single dose 250.Indeed, in this further configuration, there are no variations in thewidth of the inner passages of the absorbent material in granules 310which, therefore, is not subject to transverse direction changes; thisensures, therefore, a more constant and regular flow of the material ingranules 310 and, ultimately, a better control of the width 75, 85 ofdoses 250.

The skilled person will appreciate that the device 20, in the preferredembodiment illustrated in FIG. 2, could be made from stainless steelAISI 304, in particular those components that are in direct contact withthe absorbent material in granules 310. Indeed, the latter, being highlyhygroscopic, can trigger possible corrosion processes if it comes incontact with non-corrosion-resistant metallurgy, and possible surfacetreatments would not provide protection because they would be removed ina short time by the abrasive action of the material 310 itself.

The skilled person will appreciate, furthermore, that the outlet end 510of the nozzle 500 from which the absorbent granular material 310 flowsout may be placed at a distance 110 from the respective moving strip 50,60, which can vary, from a minimum value of 0.1 millimeters to a maximumvalue of 40 millimeters. It is clear that this variability depends onseveral factors, such as the size of the granules of the material, thequantity of material 310 required for each dose 250, as well as processparameters such as the type and nature of the strip 50, 60 to which saidabsorbent material into granules 310 is applied.

In the production method 10 illustrated in FIG. 1, the apparatus 20 ofdiscontinuous application of controlled quantities 250 of absorbentpolymer material in granules 310, according to the preferred embodimentof FIG. 2, can be used in combination with a continuous strip 50 made ofa layer of absorbent cellulose fibers, and the said application methodof the doses 250 can be carried out either when said layer 50 ofcellulose fibers is already formed, as shown in FIG. 1, or during theformation of the layer 50 itself.

In this type of production method of the absorbent structure 70, thedistance 110 between the outlet end 510 of the nozzle 500 and the sheet50 can be in the range from a minimum of 15 to a maximum of 40millimeters, with a preferred value of 30 millimeters, this is to favora more thorough mixing of the granules 310 with the constituent fibersof the support layer 50, especially in the case where the absorbentpolymer granules 310 are applied during the construction step of thesaid layer 50.

In the production method example 10′ illustrated in FIG. 6, theapparatus 20 of the discontinuous application of controlled quantities250 of absorbent polymer material in granules 310, according to thepreferred embodiment of FIG. 2, can be used to produce the absorbentstructure 80 that is produced by filling the hollow- or smallwell-formations 820 with absorbent material in granules 310 present on asheet 60, typically made of a Non-Woven material strip. The hollow- orsmall well-formations 820 of each absorbent structure 80 can be presentin array-form 810 of parallel rows 850 of cells or hollows or wells 820.

Each of the said cells or hollows 820 has a mouth profile 825, which maybe circular, as shown in FIG. 8, or hexagonal, or any other shape.

A suitable sheet for producing the absorbent structure 80 is the 10 g/m²hydrophilic SMS, code IC3EW-100 010 DB W, produced and marketed byFitesa 840 SE Main Street, Simpsonville, S.C. 29681 U.S.A.

For producing the absorbent structure 80 briefly described above, thesupport sheet 60 is conveyed on a support apparatus, which may be eithera drum or, as illustrated in FIG. 6, a belt 600, provided on its outersurface 650 with a plurality of groupings 610 of recesses 620 with theprofile that reproduces the desired shape of the cavities or wells 820.The arrays 810 are spaced at a constant pitch P that is equivalent tothe length 83 of the absorbent structure 80. The support sheet 60 isdeposited on the forming belt 600, and subjected to deformation, forexample by the action of a possible pressure roller (not present in themethod illustrated in FIG. 6), provided on its outer surface with aplurality of protrusions corresponding to the shape and position of therecesses 610 on the outer surface 650 of the belt or drum 600, incombination with the action of a sub-atmospheric pressure source 660applied on the inner surface 640 of the belt or drum 600 through avacuum distributor 670. The vacuum generated by the sub-atmosphericsource 660, thanks to the presence of air permeable surfaces 625 on thebottom of the cavities 620, when these air permeable surfaces arealongside the vacuum distributor 670, sucks the sheet 60 inside the saidcavities 620 of the forming belt 600, determining the deformation withthe consequent formation of the cavities or wells 820.

It will not escape the skilled person that the said deformationoperation can also be carried out by just one of the two devicesdescribed above, indeed, as highlighted in the diagram of FIG. 6, thedeformation of the sheet 60 is achieved only by the vacuum action.

The forming process just described is essentially similar to thetechniques of vacuum deformation of plastic material films, and can beadvantageously implemented either on belt systems or on drum apparatus,as for example described in the documents EP 1 974 705 A1 and EP 2 286776 A1.

In the production method example 10′, illustrated in FIG. 6, theapparatus 20 will deposit the dose 250 of absorbent polymer material ingranules 310 within the cavity 820 of the relative array 810 previouslyformed on the strip 60. In this particular process, the distance 110between the outlet end 510 of the nozzle 500 and the sheet 50 can bewithin a range from a minimum of 0.1 to a maximum of 5 mm, with apreferred range between 0.5 and 1 mm, so as to avoid any rebounds of theabsorbent material in granules 310 on the sheet 60 supported by the belt600, and therefore avoiding contamination in areas where the material ingranules should not be present.

In the method 10′, the deposition step of the dose 250 of the absorbentmaterial in granules 310 coincides with the construction step of thearray 810 of cavities 820; therefore, the device 20 will begin todeposit the material in granules 310 of the dose 250 in the instant inwhich the first cavities or hollows 820 present themselves under themouth or outlet end 510 of the nozzle 500, and the unloading operationwill cease when all the cavities 820 of the relative array 810 havepassed under said mouth or outlet end 510 and therefore will have beenfilled with absorbent material in granules 310.

In a further particularly preferred embodiment of the device 20, theoutlet nozzle 500 can be subdivided into a plurality of ducts separatedfrom each other along the respective width 550 and arranged alongsideone another, designed to carry out an application of material ingranules that results as being discontinuous in the Y direction,transverse to the direction of application/advancement X and to the saidsheet 50, 60.

It is evident to the skilled person that said further embodiment can beadvantageously applied in the production method 10′ illustrated in FIG.6, i.e. in the case wherein the apparatus 20 must fill, with singledoses 250 of absorbent material in granules 310, the correspondingarrays 810 formed, in turn, by a plurality of rows 850 of wells orcavities 820 parallel to each other; in this case an outlet nozzle 500can be used, provided with a series of ducts arranged next to oneanother, wherein each outlet duct is coaxial with the respective row850.

The absorbent structure 80 can be completed by sealing the absorbentmaterial in granules 310 within the hollows 820 with a further sheet ofNon-Woven material, and providing appropriate means for closing andanchoring the absorbent material in granules 310 such as, for example,mechanical systems 750 or glue-application systems 690, 700.

Of course, without prejudice to the principle of the invention, thedetails of construction and the embodiments may vary widely with respectto those described and illustrated without departing from the scope ofthe invention as defined by the claims that follow.

The invention claimed is:
 1. An apparatus for intermittently applying aflow of absorbent material in granules on a sheet, comprising: means foradvancing a continuous sheet along a direction; means for providing acontinuous and controlled flow of said absorbent material in granules; adevice for transforming said continuous and controlled flow of absorbentmaterial in granules into an intermittent flow for providing theabsorbent material in a plurality of discrete doses to said continuoussheet movable along said direction, said device including: a feedmanifold, an outlet nozzle and a main body, the main body beingpositioned between said feed manifold and said outlet nozzle, configuredto cause said absorbent material in granules to flow along a crossingdirection coinciding with respective axes of symmetry of said feedmanifold, said outlet nozzle and said main body; wherein said main bodyhouses a movable element capable of moving alternately in first andsecond opposing directions between a first and a second working positionsuch that when said movable element is located in the first workingposition, it forms a first accumulation chamber to hold a first dose ofthe absorbent material, and a first discharge duct of said material, andwhen said movable element is in the second working position, it forms asecond accumulation chamber to hold a second dose of the absorbentmaterial and a second discharge duct of said material; and means forapplying said plurality of discrete doses of said absorbent materialdischarged through said first and second discharge ducts alternately tosaid advancing continuous sheet.
 2. An apparatus according to claim 1,wherein said main body has an inner cross-section transverse to saidcrossing direction of said material through said main body in the shapeof a quadrilateral having all right angles.
 3. An apparatus according toclaim 1, wherein said movable element has a wedge shape, having a firstand a second end and two side faces, symmetrical along said crossingdirection of said flow of absorbent material in granules, convergingtoward said first end and forming with said second end a first side edgeand a second side edge, respectively; said movable element beingconnected at said second end to a shaft rotatable about an axis, theshaft being configured to allow the movable element to perform anoscillating movement about said axis between said first and secondworking positions.
 4. An apparatus according to claim 3, wherein saidmovable element is connected to actuator means configured to confer saidoscillatory movement to said movable element around said axis.
 5. Anapparatus according to claim 4, wherein said actuator means comprises aservomotor.
 6. An apparatus according to claim 1, wherein an upper partof said main body is provided with air inlets.
 7. An apparatus accordingto claim 6, wherein said air inlets comprise slots or holes.
 8. Anapparatus according to claim 1, wherein said outlet nozzle is connectedto a lower part of the main body by means of an air manifold interposedbetween said nozzle and said main body, said air manifold being providedwith an air reservoir for pressurized air shaped to wrap around an outerperimeter of said air manifold and being in fluid communication with aninterior of said air manifold.
 9. An apparatus according to claim 8,wherein an air pressure within said air reservoir is between 0.3 and 4bars.
 10. An apparatus according to claim 9, wherein the air pressurewithin said air reservoir is between 0.7 and 1.5 bars.
 11. An apparatusaccording to claim 8, wherein said air reservoir is in communicationwith said air manifold through openings placed at a connecting edge ofsaid air manifold with said outlet nozzle, and is capable of generatingan air flow at high speed within said outlet nozzle.
 12. An apparatusaccording to claim 1, wherein the outlet nozzle comprises a plurality ofducts separated from each other and arranged alongside one another,configured to carry out an application of said material in granules ontosaid receiving means, said application being discontinuous both in saiddirection of said receiving means and in a direction transverse to saiddirection.
 13. A machine for the production of an absorbent structurefor disposable sanitary hygiene products comprising the apparatusaccording to claim
 1. 14. A device suitable for transforming acontinuous and controlled flow of absorbent material in granules into anintermittent flow for providing the absorbent material to receivingmeans movable along a direction, comprising: a feed manifold, an outletnozzle and a main body, the main body being positioned between said feedmanifold and said outlet nozzle, configured to cause said absorbentmaterial in granules to flow along a crossing direction coinciding withrespective axes of symmetry of said feed manifold, said outlet nozzleand said main body; wherein said main body houses a movable elementcapable of moving alternately between a first and a second workingposition such that when said movable element is located in the firstworking position, it forms a first accumulation chamber of the absorbentmaterial, and a first discharge duct of said material, and when saidmovable element is in the second working position, it forms a secondaccumulation chamber of the absorbent material and a second dischargeduct of said material, wherein said movable element has a wedge shape,having a first and a second end and two side faces, symmetrical alongsaid crossing direction of said flow of absorbent material in granules,converging toward said first end and forming with said second end afirst side edge and a second side edge, respectively; said movableelement being connected at said second end to a shaft rotatable about anaxis, the shaft being configured to allow the movable element to performan oscillating movement about said axis between said first and secondworking positions.
 15. A device according to claim 14, wherein said mainbody has an inner cross-section transverse to said crossing direction ofsaid material through said main body in the shape of a quadrilateralhaving all right angles.
 16. A device according to claim 14, whereinsaid movable element is connected to actuator means configured to confersaid oscillatory movement to said movable element around said axis. 17.A device according to claim 16, wherein said actuator means comprises aservomotor.
 18. A device according to claim 14, wherein an upper part ofsaid main body is provided with air inlets.
 19. A device according toclaim 18, wherein said air inlets comprise slots or holes.
 20. A deviceaccording to claim 14, wherein the outlet nozzle comprises a pluralityof ducts separated from each other and arranged alongside one another,configured to carry out an application of said material in granules ontosaid receiving means, said application being discontinuous both in saiddirection of said receiving means and in a direction transverse to saiddirection.
 21. A machine for the production of an absorbent structurefor disposable sanitary hygiene products comprising a device suitablefor transforming a continuous and controlled flow of absorbent materialin granules into an intermittent flow according to claim
 14. 22. Adevice suitable for transforming a continuous and controlled flow ofabsorbent material in granules into an intermittent flow for providingthe absorbent material to receiving means movable along a direction,comprising: a feed manifold, an outlet nozzle and a main body, the mainbody being positioned between said feed manifold and said outlet nozzle,configured to cause said absorbent material in granules to flow along acrossing direction coinciding with respective axes of symmetry of saidfeed manifold, said outlet nozzle and said main body; wherein said mainbody houses a movable element capable of moving alternately between afirst and a second working position such that when said movable elementis located in the first working position, it forms a first accumulationchamber of the absorbent material, and a first discharge duct of saidmaterial, and when said movable element is in the second workingposition, it forms a second accumulation chamber of the absorbentmaterial and a second discharge duct of said material, and wherein saidoutlet nozzle is connected to a lower part of the main body by means ofan air manifold interposed between said outlet nozzle and said mainbody, said air manifold being provided with an air reservoir forpressurized air shaped to wrap around an outer perimeter of said airmanifold and being in fluid communication with an interior of said airmanifold.
 23. A device according to claim 22, wherein an air pressurewithin said air reservoir is between 0.3 and 4 bars.
 24. A deviceaccording to claim 23, wherein the air pressure within said airreservoir is between 0.7 and 1.5 bars.
 25. A device according to claim22, wherein said air reservoir is in communication with said airmanifold through openings placed at a connecting edge of said airmanifold with said outlet nozzle, and is capable of generating an airflow at high speed within said outlet nozzle.